Injection moldings and sensor modules

Abstract

To reduce influence of a weld and to obtain a toughness on an injection molded product.SOLUTION: There is provided an injection molded product 30 having a first hole 31h1 and a second hole 31h2. The injection molded product 30 comprises: a first partial annular portion 32 that surrounds the first hole 31h1 on a side opposite to the second hole 31h2; a second partial annular portion 34 that surrounds the second hole 31h2 on a side opposite to the first hole 31h1; and a connecting portion 36 that surrounds a remaining portion of the first partial annular portion 32 around the first hole 31h1, surrounds a remaining portion of the second partial annular portion 34 around the second hole 31h2, and connects the first partial annular portion 32 and the second partial annular portion 34, wherein a weld 38 is formed in the connecting portion 36.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to injection molded parts and sensor modules. [Background technology]

[0002] Patent document 1 discloses a fixing member having an insertion hole portion which is a hole portion penetrating in the thickness direction of the plate on one side in the longitudinal direction, and a through hole portion which is a hole portion penetrating in the thickness direction of the plate on the other side in the longitudinal direction. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-96828 A Summary of the Invention [Problem to be solved by the invention]

[0004] Injection molded products may have welds formed due to the joining of molten resin inside the mold. It is desirable to reduce the effect of welds and make injection molded products stronger.

[0005] Therefore, an object of the present disclosure is to reduce the effect of welds and make injection molded products stronger. [Means for solving the problem]

[0006] The injection-molded product disclosed herein is an injection-molded product having a first hole and a second hole, comprising a first partial annular portion surrounding the first hole on the side opposite the second hole, a second partial annular portion surrounding the second hole on the side opposite the first hole, and a connecting portion surrounding the remaining portion of the first partial annular portion around the first hole and surrounding the remaining portion of the second partial annular portion around the second hole, connecting the first partial annular portion and the second partial annular portion, wherein a weld is formed in the connecting portion. Effect of the Invention

[0007] According to the present disclosure, the effect of welds can be reduced, making injection molded products stronger. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic perspective view showing a sensor module according to an embodiment. [Diagram 2] FIG. 2 is a plan view showing an injection molded product. [Diagram 3] FIG. 2 is a plan view showing another injection molded product. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described.

[0010] The injection molded article of the present disclosure is as follows.

[0011] (1) An injection-molded product having a first hole and a second hole, comprising: a first partial annular portion surrounding the first hole on the side opposite the second hole; a second partial annular portion surrounding the second hole on the side opposite the first hole; and a connecting portion surrounding the remaining portion of the first partial annular portion around the first hole and the remaining portion of the second partial annular portion around the second hole, connecting the first partial annular portion and the second partial annular portion, wherein a weld is formed in the connecting portion.

[0012] In this injection molded product, the portion where the connecting portion is formed is thicker than the first partial annular portion and the second partial annular portion. Since a weld is formed in this connecting portion, the effect of the weld can be reduced, making the injection molded product stronger.

[0013] (2) In the injection-molded product of (1), the connecting portion has a shape defined by a boundary that connects the first partial annular portion and the second partial annular portion with at least one of a straight line and an outwardly protruding line when viewed along the central axis direction of the first hole. By forming a weld in the connecting portion formed thick in this way, the effect of the weld can be reduced and the injection-molded product can be made stronger.

[0014] (3) In the injection-molded product of (1) or (2), a gate mark may be formed in the connecting portion. When molten resin is poured from the gate into the connecting portion, the molten resin is thought to flow around the first hole and the second hole after passing through the connecting portion, and then return to the connecting portion to join together. This makes it easier to form a weld in the connecting portion.

[0015] (4) In the injection-molded product of (1) or (2), the first gate mark and the second gate mark may be formed in the first partial annular portion and the second partial annular portion on the opposite side to the connecting portion. In this case, when molten resin is poured from the gates at both ends, the molten resin that has passed around the first hole and the molten resin that has passed around the second hole may join at the connecting portion. This makes it easier to form a weld at the connecting portion.

[0016] The injection molded article of the present disclosure may be as follows.

[0017] (5) An injection-molded product having a first hole and a second hole, comprising: a first partial annular portion surrounding the first hole on the side opposite the second hole; a second partial annular portion surrounding the second hole on the side opposite the first hole; and a connecting portion surrounding the remaining portion of the first partial annular portion around the first hole and the remaining portion of the second partial annular portion around the second hole, connecting the first partial annular portion and the second partial annular portion, wherein a gate mark is formed on the connecting portion.

[0018] In this case, when molten resin is poured into the connecting portion from the gate, it is considered that after passing through the connecting portion, the molten resin flows around the first hole and the second hole, and returns to the connecting portion to join together. This makes it easier to form a weld at the connecting portion. The portion where the connecting portion is formed is thicker than the first partial annular portion and the second partial annular portion. Because a weld is formed at this connecting portion, the effect of the weld is reduced, making the injection molded product stronger.

[0019] The injection molded article of the present disclosure may be as follows.

[0020] (6) An injection-molded product having a first hole and a second hole, comprising: a first partial annular portion surrounding the first hole on the side opposite to the second hole; a second partial annular portion surrounding the second hole on the side opposite to the first hole; and a connecting portion surrounding the remaining portion of the first partial annular portion around the first hole and surrounding the remaining portion of the second partial annular portion around the second hole, connecting the first partial annular portion and the second partial annular portion, wherein a first gate mark and a second gate mark are formed in portions of the first partial annular portion and the second partial annular portion on the side opposite to the connecting portion.

[0021] In this case, when molten resin is poured in from the gates at both ends, it is considered that the molten resin that has passed around the first hole and the molten resin that has passed around the second hole will join at the connecting portion. This makes it easier to form a weld at the connecting portion. The portion where the connecting portion is formed is thicker than the first partial annular portion and the second partial annular portion. Because a weld is formed at this connecting portion, the effect of the weld is reduced, making the injection molded product stronger.

[0022] The sensor module 20 of the present disclosure is as follows.

[0023] (7) A sensor module comprising: a sensor; a sensor holder for holding the sensor; an injection-molded product selected from any one of (1) to (6) in which at least a portion of the sensor holder is disposed within the first hole; and an electric wire extending from the sensor through the holder to the outside.

[0024] According to this sensor module, the first hole of the injection molded product can be used to hold the injection molded product in the sensor holder, and the second hole can be used to screw the injection molded product to a fixing target location, etc. In this way, the injection molded product that holds the sensor can be made sturdy.

[0025] [Details of the embodiment of the present disclosure] Specific examples of the injection molded product and the sensor module of the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0026] [Embodiment] The injection-molded product and the sensor module according to the embodiment will be described below. Fig. 1 is a schematic perspective view showing a sensor module 20 including an injection-molded product 30.

[0027] The sensor module 20 includes a sensor 22, a sensor holder 24, an electric wire 26, and an injection-molded product 30. The sensor 22 is connected to an end of the electric wire 26. The sensor holder 24 covers the sensor 22 and the end of the electric wire 26. One end of the injection-molded product 30 is attached to the sensor holder 24, and the other end of the injection-molded product 30 protrudes outside the sensor holder 24. The sensor holder 24 holding the sensor 22 is fixed to a target location via the injection-molded product 30. This allows the sensor 22 to be held in a predetermined position and in a predetermined attitude near the target location. The injection-molded product 30 is a bracket that supports the sensor 22 and the sensor holder 24.

[0028] More specifically, the sensor 22 is an element that detects physical quantities such as magnetism, light, temperature, etc., or changes therein. The electric wire 26 is connected to the sensor 22. The electric wire 26 is connected to a terminal of the sensor 22 by soldering, crimping, etc. The electric wire 26 may or may not be covered by a sheath.

[0029] The sensor holder 24 covers the sensor 22 and the end of the electric wire 26. The sensor holder 24 is formed in an elongated shape, for example, a cylindrical shape. The sensor 22 is disposed in one end of the sensor holder 24. The electric wire 26 passes through the sensor holder 24 from the sensor 22 in the sensor holder 24 and is drawn out from the other end face of the sensor holder 24 to the outside. The sensor holder 24 is, for example, a resin part molded with the sensor 22 and the electric wire 26 as an insert part. The sensor holder 24 may be a composite of multiple parts. For example, the sensor holder 24 may be a composite of an inner resin holder that holds the sensor 22 and the electric wire 26 and an outer resin part that covers the inner resin holder.

[0030] The injection molded product 30 is an injection molded product having a first hole 31h1 and a second hole 31h2. At least a part of the sensor holder 24, here, a longitudinal middle part of the sensor holder 24, is disposed in the first hole 31h1, so that the injection molded product 30 is attached to the sensor holder 24. In this state, the part of the injection molded product 30 where the second hole 31h2 is formed protrudes outward from the sensor holder 24. Then, the injection molded product 30 is screwed to a fixing target location using the second hole 31h2.

[0031] The injection molded product 30 is formed by injection molding in a mold with the sensor holder 24 covering the sensor 22 and the electric wire 26 as an insert part. Thus, the first hole 31h1 is a hole formed by the sensor holder 24. The second hole 31h2 may be formed by the mold surface of the mold, or may be formed by another part placed in the mold. In this embodiment, the metal annular part 40 is placed in the part where the second hole 31h2 is formed. The metal annular part 40 may be a part called a metal bush. The outer peripheral surface of the metal annular part 40 forms the second hole 31h2.

[0032] The sensor module 20 is used, for example, as a sensor for detecting the rotation speed of a wheel of a vehicle. More specifically, the sensor module 20 may be used as a sensor for an ABS (antilock braking system).

[0033] FIG. 2 is a plan view showing the injection molded product 30. As shown in FIG. 1 and FIG. 2, the injection molded product 30 has a shape in which two semicircular plate-shaped parts are connected via a rectangular plate-shaped part. The injection molded product 30 may have an oval plate shape. The injection molded product 30 has a first hole 31h1 and a second hole 31h2. The first hole 31h1 is formed near one end of the injection molded product 30 in the longitudinal direction, and the second hole 31h2 is formed near the other end of the injection molded product 30 in the longitudinal direction. The first hole 31h1 and the second hole 31h2 penetrate the injection molded product 30 in the thickness direction. The central axis of the first hole 31h1 and the central axis of the second hole 31h2 are parallel to each other. The first hole 31h1 and the second hole 31h2 do not need to be circular, and may be an elongated hole or a polygonal hole shape.

[0034] The injection-molded article 30 includes a first partial annular portion 32 that surrounds the portion around the first hole 31h1 on the opposite side to the second hole 31h2. The first partial annular portion 32 is a semi-annular portion on one end side of the injection-molded article 30 in the longitudinal direction among the portion surrounding the first hole 31h1.

[0035] The injection-molded article 30 includes a second partial annular portion 34 that surrounds the second hole 31h2 on the opposite side to the first hole 31h1. The second partial annular portion 34 is a semi-annular portion on the other end side of the injection-molded article 30 in the longitudinal direction among the portion surrounding the second hole 31h2.

[0036] The injection molded product 30 includes a connecting portion 36 that connects the first partial annular portion 32 and the second partial annular portion 34. The connecting portion 36 surrounds the remaining portion of the portion surrounded by the first partial annular portion 32 around the first hole 31h1, and surrounds the remaining portion of the portion surrounded by the second partial annular portion 34 around the second hole 31h2. In other words, the connecting portion 36 surrounds the portion of the first hole 31h1 on the second hole 31h2 side, and surrounds the portion of the second hole 31h2 on the first hole 31h1 side. The connecting portion 36 is formed so as to fill the gap when it is assumed that the first hole 31h1 and the second hole 31h2 are surrounded by annular portions. More specifically, when viewed along the axial direction of the first hole 31h1 or the second hole 31h2, the connecting portion 36 has a shape defined by a boundary 36L that connects the first partial annular portion 32 and the second partial annular portion 34 with at least one of a straight line and an outwardly convex line (which may be a line that draws an angle that is convex outward, or a line that draws a curve that is convex outward). For example, both outer boundaries 36L of the connecting portion 36 connect the widest portion of the first partial annular portion 32 and the widest portion of the second partial annular portion 34 with a boundary L that is a straight line, a line that is convex outward, or a combination thereof. In the width direction perpendicular to the arrangement direction of the first hole 31h1 and the second hole 31h2, the width of the connecting portion 36 is equal to or larger than the smaller of the maximum width of the first partial annular portion 32 and the maximum width of the second partial annular portion 34.

[0037] A weld 38 is formed in the connecting portion 36. A weld is a portion formed as a trace of molten resin joining together inside a mold when injection molding the injection-molded product 30 using the mold. Since the leading end of the molten resin flowing inside the mold is cooled and solidified, the joining portion of the molten resin inside the mold is considered to be observed as a streaky discolored portion, which is the joining portion of the molten resin that has been cooled and solidified.

[0038] In order to form the weld 38 in the connecting portion 36, it is considered that in the mold 50 for molding the injection-molded product 30, a gate 52 is formed at a position where molten resin is poured into the connecting portion 36 (see FIG. 2). More specifically, it is considered that the gate 52 opens on one side in a direction perpendicular to both the direction in which the first hole 31h1 and the second hole 31h2 are arranged and the central axis direction of the first hole 31h1 or the second hole 31h2 with respect to the mold space forming the connecting portion 36, and that the molten resin is poured from the gate 52 into between the first hole 31h1 and the second hole 31h2. In this case, it is considered that the molten resin flows from the connecting portion 36 through the periphery of the first hole 31h1 and the second hole 31h2 as shown by the flow F1 and flows into the portion of the connecting portion 36 near the gate 52. For this reason, it is considered that the weld 38 is formed in the portion of the connecting portion 36 near the gate 52.

[0039] After injection molding, the weld 38 may not be clearly visible and may be difficult to observe. A gate mark 39, which is a trace of the gate 52, may be formed on the side of the connecting part 36 as a partially protruding portion of the surface. However, the gate mark 39 may be difficult to observe due to subsequent processing such as cutting and polishing.

[0040] 1 and 2, it is also possible to form the gate 152 so as to open in a portion of the mold space forming the first partial annular portion 32 on the opposite side to the connecting portion 36, and in a portion of the mold space forming the second partial annular portion 34 on the opposite side to the connecting portion 36, as in the injection-molded product 130 shown in Fig. 3. In other words, this is a case where two gates 152 are formed at both ends of the injection-molded product 30 in the longitudinal direction in the mold space forming the injection-molded product 30.

[0041] In this case, when molten resin is poured from the two gates 52, the molten resin is thought to split into two in the width direction of the injection-molded product 30 as shown by flow F2, flow around the first hole 31h1 and the second hole 31h2, and join at the connecting portion 36. For this reason, it is thought that the weld 38 is formed at the connecting portion 36.

[0042] In this example as well, the weld 38 may not be clearly visible after injection molding and may be difficult to observe. The first gate mark 139 and the second gate mark 139, which are traces of the two gates 152, may be formed on the partial surfaces of the first partial annular portion 32 and the second partial annular portion 34 on the opposite side to the connecting portion 36 as partially protruding portions of the surface. However, as described above, the gate mark 139 may be difficult to observe due to subsequent processing such as cutting and polishing.

[0043] According to the injection molded product 30 and the sensor module 20 configured in this manner, the weld 38 is formed in the connecting portion 36. The portion of the injection molded product 30 where the connecting portion 36 is formed is thicker than the first partial annular portion 32 and the second partial annular portion 34. Therefore, even if the portion of the injection molded product 30 where the weld 38 is formed is weaker than other portions, cracks that divide the portion surrounding the first hole 31h1 or the portion surrounding the second hole 31h2 in the circumferential direction are unlikely to occur. Therefore, the effect of the weld 38 can be reduced, making the injection molded product 30 stronger. This makes it possible to suppress the occurrence of defective products when the injection molded product 30 is molded with a metal mold.

[0044] The connecting portion 36 may have a shape defined by a boundary L that connects the first partial annular portion 32 and the second partial annular portion 34 with at least one of a straight line and an outwardly protruding line when viewed along the central axis direction of the first hole 31h1. Such a connecting portion 36 is thicker than the first partial annular portion 32 and the second partial annular portion 34 along the radial direction of the first hole 31h1 or the second hole 31h2. Since the weld 38 is provided in this connecting portion 36, the effect of the weld 38 can be reduced, making the injection-molded product 30 stronger.

[0045] Furthermore, if the gate mark 39 is formed in the connecting portion 36, it is considered that the injection-molded article 30 is designed so that the resin poured into the connecting portion 36 from the gate 52 flows around the first hole 31h1 and the second hole 31h2 after passing through the connecting portion 36, and then returns to the connecting portion 36 to join together. In this case, even if the weld 38 is difficult to observe in the injection-molded article 30, the injection-molded article 30 can be made sturdy.

[0046] Furthermore, if the first gate mark 139 and the second gate mark 139 are formed in the first partial annular portion 32 and the second partial annular portion 34 on the side opposite the connecting portion 36, it is considered that the injection-molded article 30 is designed such that the molten resin poured from one gate 152 flows in two around the first hole 31h1, and the molten resin poured from the other gate 152 flows in two around the second hole 31h2, and these two flows of molten resin join at the connecting portion 36. In this case, even if the weld 38 is observed in the injection-molded article 30 or is difficult to observe, the injection-molded article 30 can be made sturdy.

[0047] Moreover, according to the sensor module 20 including the injection molded product 30, at least a part of the sensor holder 24 is disposed in the first hole 31h1, and the injection molded product 30 is attached to the sensor holder 24. The first hole 31h1 serves to hold the sensor holder 24, and the second hole 31h2 serves as a hole for screwing the sensor holder 24 to a fixing target location. As described above, since the weld 38 is formed in the connecting portion 36, cracks that would separate the parts around the first hole 31h1 or the second hole 31h2 are unlikely to occur. This makes it possible to manufacture a sensor module 20 having a sturdy injection molded product 30 as a fixing part.

[0048] [Variations] In the embodiment, a case has been described in which the injection-molded product 30 is used as a part of the sensor module 20. The injection-molded product 30 is not limited to being used as a part of the sensor module 20, and may be applied to various parts having a first hole and a second hole.

[0049] The configurations described in the above embodiment and modifications can be combined as appropriate as long as they are not mutually inconsistent. [Explanation of symbols]

[0050] 20 Sensor Module 22 Sensors 24 Sensor holder 26 Electric wire 30, 130 Injection molded products 31h1 1st hole 31h2 2nd hole 32 First partial annular portion 34 Second partial annular portion 36 Connecting part 36L Boundary 38 Weld 39, 139 Gate ruins 40 Metal ring parts 50 Mold Gates 52 and 152

Claims

1. An injection molded article having a first hole and a second hole, The two semicircular plate-shaped portions are connected via a rectangular plate-shaped portion to form a plate shape or an elliptical plate shape, and the first hole and the second hole are formed in the plate-shaped portion, a first partial annular portion surrounding the first hole on a side opposite to the second hole; a second partial annular portion surrounding the second hole on a side opposite to the first hole; a connecting portion that surrounds a remaining portion of the first partial annular portion around the first hole and surrounds a remaining portion of the second partial annular portion around the second hole, and connects the first partial annular portion and the second partial annular portion; Equipped with the connecting portion is thicker than the first partial annular portion and the second partial annular portion, An injection-molded product, wherein a weld is formed at the connecting portion.

2. The injection molded article according to claim 1, The connecting portion is an injection molded product having a shape defined by a boundary connecting the first partial annular portion and the second partial annular portion with at least one of a straight line and an outwardly convex line when viewed along the central axial direction of the first hole.

3. The injection molded product according to claim 1 or 2, An injection molded product, wherein a gate mark is formed in the connecting portion.

4. The injection molded product according to claim 1 or 2, An injection molded product, wherein a first gate mark and a second gate mark are formed in portions of the first partial annular portion and the second partial annular portion opposite the connecting portion.

5. An injection molded article having a first hole and a second hole, The two semicircular plate-shaped portions are connected via a rectangular plate-shaped portion to form a plate shape or an elliptical plate shape, and the first hole and the second hole are formed in the plate-shaped portion so as to penetrate the plate-shaped portion in a thickness direction, a first partial annular portion surrounding the first hole on a side opposite to the second hole; a second partial annular portion surrounding the second hole on a side opposite to the first hole; a connecting portion that surrounds a remaining portion of the first partial annular portion around the first hole and surrounds a remaining portion of the second partial annular portion around the second hole, and connects the first partial annular portion and the second partial annular portion; Equipped with the connecting portion is thicker than the first partial annular portion and the second partial annular portion, An injection molded product, wherein a gate mark is formed at the connecting portion.

6. An injection molded article having a first hole and a second hole, The two semicircular plate-shaped portions are connected via a rectangular plate-shaped portion to form a plate shape or an elliptical plate shape, and the first hole and the second hole are formed in the plate-shaped portion, a first partial annular portion surrounding the first hole on a side opposite to the second hole; a second partial annular portion surrounding the second hole on a side opposite to the first hole; a connecting portion that surrounds a remaining portion of the first partial annular portion around the first hole and surrounds a remaining portion of the second partial annular portion around the second hole, and connects the first partial annular portion and the second partial annular portion; Equipped with the connecting portion is thicker than the first partial annular portion and the second partial annular portion, An injection molded product, wherein a first gate mark and a second gate mark are formed in portions of the first partial annular portion and the second partial annular portion opposite the connecting portion.

7. A sensor; A sensor holder for holding the sensor; 7. The injection molded product according to claim 1, wherein at least a portion of the sensor holder is disposed in the first hole; and an electric wire extending from the sensor through the holder to the outside; A sensor module comprising:

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